The new battery box is aluminum channel with a tin floor. The fuse holder is mounted for easy access.
The original was a little shallow for the new Ping 24v 15ah pack but the new one fits perfectly.
I made a new control box up front to house the controller, switches and wattmeter. I am not totally satisfied how this part turned out, so it may get a rework at some point. The switch in the side is a battery disconnect.
Unfolded dimensions are 42l x 26w x 35.5h, so it is comparable to production scooters and larger than the compact travel scooters. Weight is about 56.5lb. Folded dimensions are 33l x12w x18h. It's only 10.5"wide but the tires stick past the sides. The suitcase is there for reference.
Things still to do:
Make a front fender and chain guard.
Remove or disable the freewheel.
I left it on to reduce power consumption, which it does, but having some motor drag on the downhills would help out the brake. I'm open to suggestions on an easy way to do this.
Find a way to limit the top speed, preferably without having to change the gearing.
It does 13-14kph which is still too fast for a mobility scooter and has lots of torque. Does anyone know an easy way to limit the speed of a hall effect throttle?
Change the heavy gauge wiring connectors Andersons. I didn't get them in time for the initial assembly.
I may also try the 250w motor/controller just to see which one woks best for the application.